Digital commissioning of automation systems with X-Pact^® Plug & Work integration test

We employ X-Pact^® Plug & Work not only for cold commissioning projects but also for virtual hot commissioning. The procedure for checking the drive interfaces, measuring systems, or the interfaces with all other packages is the same as that used on site. Once the individual plant modules have been tested, these are combined to create an integrated system, and the interaction between them is checked. The virtual production tests are then carried out based on the production schedule for the customer's plant.  The production reports and IBA-PDA data generated in this way with Plug & Work are evaluated jointly with SMS group's technology and safety experts before the plant is delivered.

With over 150 years of expertise in plant construction and process engineering, we know exactly how processes behave and what settings need to be made to achieve certain product properties. This is how high levels of safety and quality are guaranteed right from the start, meaning production can be started almost straight away, and smooth operation of the plant and a rapid return on investment can be achieved. Our customers' satisfaction speaks for itself.

We attach a great deal of importance to training our customer's employees under realistic conditions in our close partnership with the customers themselves. During training, for example, employees have the opportunity of contributing their own ideas and feedback. This ensures the customer's team is fully integrated into the commissioning process, so this practice-oriented approach enables them to actively assist with getting the plant on stream quickly. The operating and maintenance personnel are trained on the original control pulpits using the digital twin. Individual sessions involving one-to-one familiarization with the plant functions are conducted, and training on how to handle operational situations is carried out in virtual production mode.

Peter Waldhoff, Project Manager at SMS group, explains why customer training is so important: "Our objectives are to gain trust, to ensure that the maintenance and operating personnel identify with the project and the plant, and to achieve high levels of acceptance and teamwork. We see through the same lens as our customers. From the kick-off meeting at the latest, we share a common position and understanding not only of quality, time, costs, and safety, but also of the social competence of the customer's team, because this is just as important for the success of the project. The integration test is the time for interaction between commissioning engineers, maintenance personnel, and operators. In my experience as a project manager, it is not necessary to have the best players, but to bring together the best team."

Each plant simulation is unique and precisely tailored to the customer's plant. For the operator in the test field it feels like working on the actual plant, because all operating modes and processes are simulated in real time and visualized accordingly.

Furthermore, the concept has been enhanced to meet the requirements of the new industrial era, so that the digital commissioning of the plant and the training sessions can also be successfully completed virtually. During the pandemic, in particular, SMS group was required to expand its remote activities during project handling in order to protect the health of its customers and staff.

The motto here is simple: If the customer can't come to the test field, the test field goes to the customer! Training usually takes place during the "face to face" integration test. Due to the travel restrictions relating to the COVID-19 pandemic, we developed an alternative training method – remote-supported operator training in the integration test field.

Our solution is to transmit the entire simulation to the customer and to allow him access to the control units, including the virtualized control stations and local panels as well as the HMI system. The training takes place completely virtually. The customer operates the plant from his office. Trainers from SMS are on hand in a parallel video conference to answer any questions.

With X-Pact^® Service we have a perfect infrastructure for remote support during and after commissioning. As a general rule, we supply the technical option of remote support with every new plant. We use AR glasses at the equipment via a secure X-Pact^® Service Portal connection that allows us to interact directly with the customer's experts via chat, audio, video or whiteboard functions.  The tool is used during engineering, the X-Pact^® Plug & Work integration test, and commissioning activities. What's more, a mobile version of the X-Pact^® Service Portal has now been created that enables the customer's staff to initiate a service call directly from their smartphone. Therefore, within the global network of SMS group, both software experts and technologists from the development departments are available to answer any questions their customers may have. In this way, any unclear issues can be resolved straight away. This reduces overall costs and boosts the plant's performance.

No time-consuming troubleshooting, but rather proper expert support and well-functioning just-in-time partnerships.